1. Decreased heat transfer efficiency: Scaling forms a dense, hardened sludge layer that adheres tightly to the heat exchange surface, significantly increasing thermal resistance. This reduces heat transfer efficiency, requiring more energy to maintain drying performance, and potentially raising exhaust gas temperature by 5-15%.
2. Reduced drying efficiency: Scaling reduces the effective heat transfer area, prolonging the drying time. Initially, increased temperature compensation may be necessary, but in the long run, insufficient heat exchange will prevent the moisture content from meeting standards, leading to a continuous decline in product yield.
III. Equipment Malfunctions
Mechanical Failure: Scale buildup may detach and jam the impeller shaft, causing motor overload or damage to the transmission system.
Seal Failure: Accumulated scale may compress seals, leading to material or steam leakage.
Temperature Runaway: Localized scale buildup can cause the metal wall temperature to rise, potentially leading to deformation or pipe rupture.
IV. Other Derivative Issues
Environmental Pollution: Undried sludge may leak during shutdown cleaning, producing foul odors.
Maintenance Costs: Frequent shutdowns for manual cleaning increase labor and spare parts replacement costs.
Product Contamination: Scale contamination with materials may affect the quality of the finished product.
